From pit lane to the powertrain, additive manufacturing is reshaping the way race cars are designed, built, and fine-tuned in motorsports.
Rapid Iteration, Real-Time Fitment
Imagine waiting weeks for a custom transmission from halfway across the globe—only to find out it doesn’t fit. That’s a nightmare motorsports teams can’t afford. With industrial 3D printing, issues like these are solved instantly. In one case, a carbon fiber nylon bell housing was printed in just a few hours to test fitment before final machining. The part worked perfectly, saving thousands of dollars and countless hours.
McLaren’s Lesson in CAD Miscommunication
This problem isn’t hypothetical. McLaren once received a $2 million Honda F1 engine that didn’t fit due to a CAD error. With additive manufacturing, a $4-$20 printed mockup could’ve prevented that. Today, teams are using 3D printing to test, fit, and refine—on the fly, at a fraction of the cost.
Exotic Materials Like Ultem 1010 Are Game-Changers
High-performance thermoplastics like Ultem 1010 are shifting how we think about under-hood components. With incredible heat resistance, chemical tolerance, and structural integrity, parts once reserved for metal can now be printed and installed—everything from intake components to downpipes. Even in “vase mode” with a 0.4mm nozzle, Ultem parts are so strong you can stand on them. Literally.
From Clip Replacements to Full-On Body Kits
The beauty of additive manufacturing lies in customization and accessibility. Can’t find that discontinued clip or panel? Print it. Want to design a custom body kit or OEM-style restoration piece? Print it. Even classic car restoration is becoming easier as enthusiasts print the parts they can’t find anywhere else.
Industrial-Grade Additive Solutions on the Track
Race teams are now traveling with industrial 3D printers like the 22 IDEX, printing usable components in real-time—from nacaducts to brake ducts. With thermoplastics that can handle 245°C and resist any automotive chemical, the technology is no longer limited to prototyping—it’s race-day ready.
Shhh…It’s Already in Use
Why isn’t this more widely known? Because the competitive edge is massive. F1 teams and manufacturers are quietly integrating high-temp thermoplastics and even metal 3D printing into their vehicles. Ford and Honda, for instance, are already using metal printed turbos. Honda even published a Japanese article showing 3D-printed titanium parts being post-processed with grinders and chisels.
Generative Design and the Czinger Revolution
Companies like Czinger are pushing the envelope even further. Their hypercar, the 21C, leverages generative AI to produce a 3D-printed frame that combines multiple components—uprights, calipers, suspension arms—into a single part. This isn’t theoretical anymore. This is the bleeding edge of automotive engineering.
Customization Without Compromise
Additive manufacturing allows engineers to iterate at the speed of thought. Need a new aerodynamic fin for a slight downforce gain? Print it. Want to test a redesigned intake between practice sessions? Done. You don’t need to retool an entire line—just hit print. Teams can now create race-specific upgrades with minimal cost and lead time.
Metal 3D Printing: From Engine Blocks to Turbos
The future of motorsports isn’t just plastic—it’s metal. With machines like SLM (Selective Laser Melting) and DMLS (Direct Metal Laser Sintering), entire powertrain components are being printed. Not just brackets or manifolds—we’re talking turbos, blocks, and more. The design freedom this brings is unmatched, enabling complex geometries and reduced part counts previously impossible.
It’s Not the Future—It’s Already Here
The reality is that additive manufacturing isn’t the future of motorsports—it’s the present. The pace of innovation in 3D printing materials and technology is outstripping the speed at which teams—and even fans—can keep up. But those who embrace it will have a serious edge, both on and off the track.
Let’s Build Something Together
If you’ve got an idea for a 3D-printed car part—or even something you thought could never be printed—now’s the time. The technology is here. The materials are ready. All that’s missing is your vision.
Drop your ideas below, and let’s bring the next generation of motorsports parts to life.
Ready to get started? Visit Vision Miner to explore industrial-grade 3D printing and scanning solutions, including the 22 IDEX and more.